Concrete block and system for its use in the construction of housing units

ABSTRACT

A concrete block for the construction of housing units is disclosed. The block disclosed herein allows for an improved low cost manufacturing, without the use of forming systems and without special tools, an ample array of structural elements that serve for the construction of walls for housing units and edifications of one or various levels, contention walls, spaces between floors and load carriers for doors and windows in the field of reinforced masonry, thereby synthesizing and improving, with the use of just one element, the principal characteristics inherent of the existing constructive systems.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

[0001] N/A

RELATED APPLICATIONS

[0002] This application claims foreign priority and the benefit of the filing date of the application entitled “Mejoras al Bloque de Concreto del Sistema Constructivo Prefabricado y su Utilizacion en la Construccion de Viviendas” filed with the Department of Patents of Invention of the Registry of Industrial Property of Costa Rica on May 9, 2002, which is incorporated by reference herein as if fully set forth in its entirety, and which constitutes an improvement to the Utility Model registered under number 150, denominated “Sistema Constructivo Prefabricado y su Utilizacion en la Construccion de Viviendas” whose application number was 5654.

BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] The present invention relates generally to prefabricated construction systems for housing construction and, more specifically, to a concrete block used in said systems and its use in the construction of housing offering the user the ability to build a structure in-site at a low cost and with minimal equipment.

[0005] 2. Discussion of the Background

[0006] Present day masonry practices may be separated into three major groups as follows:

[0007] a. Confined masonry structures (concrete blocks placed in stack or interlocked and confined by reinforced concrete frames, said frames constructed in-situ or prefabricated; the frames also may be constructed with other types of materials different from concrete).

[0008] b. Reinforced masonry structures (concrete blocks placed in stack or interlocked, forming a structural element by means of the placement of reinforcing steel in their cells and filling the same with concrete).

[0009] c. A hybrid of groups a and b.

[0010] Lightened concrete blocks of great length, produced by vibrocompression, are used only in the confined masonry practices group, where utility model 150 (“MU 150”) of Costa Rica, titled “Prefabricated Construction System and its use in the Construction of Housing” has its preferred field of application.

[0011] The aforesaid device and method in the prior art, however, needs to be improved in accordance with the construction requirements of our day and age. There is a need for an improved block such as the one used in the aforesaid MU-150 by implementing special geometric cavities at the ends of said block, which represents a significant innovation in the use of reinforced masonry. There is a need for a Concrete Block and System for its Use in the Construction of Housing Units which overcomes these and other deficiencies in the prior art.

[0012] The block of the invention belongs to the technology sector of the production of construction materials and its application in the sector of construction of housing and edifications.

[0013] The production of the block of the invention is accomplished with the standard machinery present in the majority of the companies which manufacture concrete blocks, requiring only that the mold for the block of the invention is installed in the machinery.

SUMMARY OF THE INVENTION

[0014] The object of the present invention is to provide a block for the low-cost construction of housing units.

[0015] It is a further object of the present invention to provide a block made from an inexpensive material.

[0016] It is another object of the present invention to provide a block which enables the rapid erection of a building or structure which can be assembled on site using minimal skills.

[0017] The block itself, both as to its construction and its mode of operation, will be best understood, and additional objects and advantages thereof will become apparent, by the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings.

[0018] When the word “invention” is used in this specification, the word “invention” includes “inventions”, that is, the plural of “invention”. By stating “invention”, the Applicant does not in any way admit that the present application does not include more than one patentably and non-obviously distinct invention and Applicant maintains that the present application may include more than one patentably and non-obviously distinct invention. The Applicant hereby asserts, that the disclosure of the present application may include more than one invention, and, in the event that there is more than one invention, that these inventions may be patentable and non-obvious one with respect to the other.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 is a front view of the block of the invention;

[0020]FIG. 2 is a planar view of the joinder of two blocks in collinear form;

[0021]FIG. 3 is a planar view of the joinder of the edges of two blocks of the invention;

[0022]FIG. 4 is a planar view of a joinder of two blocks of the invention in T;

[0023]FIG. 5 is an elevation view of the use of the blocks of the invention as holders of doorways or windows;

[0024]FIG. 6 is a sectional view of the use of the blocks of the invention as elements of mezzanines or reinforced slab for floors;

[0025]FIG. 7 is a sectional view of the blocks of the invention as a bond-beam;

[0026]FIG. 8 is an isometric view of a wall in construction with the blocks of the invention.

[0027] The use of the same numerals in the different views of the drawings shall be a reference to the same structures, parts, or elements, as the case may be.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0028] The improvement to the block patented in MU 150, with the introduction of cavities of special geometry at the ends of the block, results in a new lightened concrete block produced by the technology of vibrocompaction. The production of this new block is performed in standard machinery present in the majority of the makers of concrete blocks, requiring only a mold that is created exclusively for the production of the block of the invention, which may be installed in conventional machinery.

[0029] The block of the invention comprises a lightened concrete block produced by the technology of vibrocompaction with the following characteristics:

[0030] a. Minimum length of 80 centimeters and maximum length which depends on the capacity of the block production equipment and the operational maneuverability of the element.

[0031] b. Modular geometry in its interior holes that allows the block to be cut in shorter dimensions without losing its application characteristics, to satisfy the different dimensions of housing and edification units.

[0032] c. Variable width according to the use preferences or the requirements of the legal codes of the places of application.

[0033] d. Variable height according to the use preferences or the requirements of the legal codes of the places of application.

[0034] e. Ends of special geometry, forming cavities of variable depth according to the use preferences or the requirements of the legal codes of the places of application, that allow the storage of the reinforcing steel and the concrete necessary to guarantee the structural rigidity. Optionally, and for its application as a bond-beam, the block may be reduced conveniently to the height of the transversal walls.

[0035] f. The rest of the dimensions and interior geometry of the concrete block respond to the structural design technical criteria, industrial production process, transportation, management, and placement of the blocks.

[0036] The lightened concrete block as shown in FIG. 1 to be used in reinforced masonry, has among its characteristics a minimum length (L) of 80 cm. The maximum length will depend on the capacity of the technological production of the blocks and the operational maneuverability of the element. The modular geometry present in the block's interior holes permits the cutting of the element in smaller dimensions without losing its application characteristics, which allows satisfying the different dimensioning in housing and edifications (d1-d2).

[0037] The width (A) and the height (H) of the block of the invention are variable according to the preferences of use or the requirements of the codes in the location of the application. The ends with special geometry, form cavities of variable depth (p) in accordance with the preferences of use or the requirements of the location of the application, as long as they permit the housing of the reinforced steel and the concrete necessary to guarantee the structural rigidity, optionally and for its application as a bond-beam, may be decreased conveniently to the height of the transversal walls to a value (t), the rest of the dimensions and interior geometry of the concrete block responds to technical structural design criteria, industrial production process, transport, manipulation and placement of the product (e1-e2).

[0038] The improvement of the lightened concrete block results in the following advantages in the prefabricated construction system:

[0039] a. Structural homogeneity due to the use of a single element that results in an improved behavior facing the seismic, wind, and earth pressure loads.

[0040] b. Lesser length of mortar junctions by square meter of masonry (vertical junctions are eliminated and the size of the block is increased), which produces a more reliable value of the prismatic resistance (f′m) of the block, by depending more on the value of the block's resistance (produced industrially with better control) and less than the cementing mortar's resistance (produced at the construction site with lesser control).

[0041] c. Contrary to the conventional reinforced masonry practice, this system eliminates the need to raise the blocks to introduce them through the vertical rods of the reinforcing steel, which produces a better structural behavior from the masonry, by eliminating possible vacuums inside the concrete in the cells, the cementing mortar is not fractured, and the ductility of the steel is not reduced, as it is known, that the movement or the folding of the vertical steel during the placement of the blocks in the conventional form produces these faults.

[0042] d. It eliminates the loss of resistance characteristic of the block in stack of conventional masonry as the cementing mortar in the vertical junctions does not exist, which also allows for increased productivity in the placement without losing resistance.

[0043] e. The use of a block of great size, allows the application of isolated foundations solutions, which constitutes an innovation in reinforced masonry, fundamentally in housing and single level edifications, with an important savings in excavations, reinforcement steel, forming systems, and concrete.

[0044] f. It allows the construction of door and windows carriers up to vessels of 1.8 meters using the block of this invention as a structural element, with the consequential savings in work force and materials forming systems, reinforcement steel, and concrete).

[0045] g. Having incorporated the cavities in special geometric form at the ends of the block protected by MU-150, allows for a high reduction in the use of forming systems in the construction of walls and structural elements.

[0046] h. The incorporation of the block to the system as a bond-beam element is accomplished by the convenient reduction of the height of the transversal walls of the block.

[0047] i. It allows the construction of a housing unit with a minimal work force index (possibly with only one worker) and, in addition, it increased the productivity in the placement by accomplishing a greater wall area by unit of masonry placed and with a lesser quantity of joinders.

[0048] j. The previously mentioned special geometry of the block, was conceived in such a way so that its dimensions are modular, allowing the diversity of dimensions required in housing and building construction, as the special geometric form cavity is repeated in each of its cells.

[0049] k. Advantages of other construction systems which are also present in the block of the invention, such as: smooth walls, low cost, versatility of application (from social interest housing to high level housing), excellent thermoacustic behavior, susceptibility to assimilate any type of finish, electromechanical installations hidden, use in contention walls and mezzanines or reinforced slabs for floors and compatibility to interact with other construction systems.

[0050] In addition, as it may be observed and confirmed in FIG. 8, the realization of a wall using the block of this invention. The method of construction begins either from isolated 3 or continuous 8 foundations, next the reinforcement steel is placed, which may consist of rods 2 or of armed columns 7, which columns are embedded in said foundations. Next the entire 1 or cut 6 blocks are placed according to the dimensions of the edification and according to their position to conform the colineal joinders 11, in L shape 10 or in T shape 9. A horizontal reinforcement 4 is placed in the corners or spaced in accordance with the requirements of the structural design) Steel pins 5 reinforce the T unions 9.

[0051] The block 1 is used as a load carrier for doors and windows by means of a provisional support frame 13, the addition of steel hooks for suspension 12 and the incorporation of vertical reinforcement steel 14.

[0052] The wall is closed in its top end with a crown beam 15, designed in accordance with the structural requirements and to which all the elements that conform the vertical reinforcement steel are duly fixed. Optionally, the bond-beam described in FIG. 7 may be used for the construction of the crown beam 15 and windows and doors load carriers.

[0053] For the placement of the blocks 1 and 6, a conventional cementing mortar is used.

[0054]FIG. 1 shows a lightened block produced by means of the technology of vibrocompaction, with minimum and maximum lengths, of modular geometry forming cavities of variable depths, which permit the storage of the reinforcing steel and the concrete necessary to guarantee the structural rigidity.

[0055]FIG. 2 shows a planar view of the union of two blocks in collinear form, indicating in schematic form the location of the reinforcing steel as well as the area to be filled with concrete.

[0056]FIG. 3 shows a planar view of the joinder of the edges of two blocks of the invention. It also shows the placement of the reinforcing steel and the area to be filled with concrete. It is noted that to effectuate this joinder one of the lateral faces of the cavity must be cut. This type of joinder requires, by exception, the placement of a small squad of forming systems in its exterior edge.

[0057]FIG. 4 shows a planar view of a T joinder. It also shows the zone of reinforcing steel placement and the concrete filling area. In addition, FIG. 4 shows the cut zones in the block to effectuate this joinder.

[0058]FIG. 5 shows an elevation view and the form to use the blocks of the invention as load carriers for windows and door frames.

[0059]FIG. 6 is a sectional view of the use of the blocks of the invention as elements of mezzanines or reinforced slabs for floors. It also shows the reinforcing steel and concrete filling zone.

[0060]FIG. 7 is a sectional view of the blocks of the invention as a bond-beam.

[0061]FIG. 8 is an isometric view of a wall in the construction phase with the blocks of the invention.

[0062] Thus, there has been shown and described a concrete block and system for its use in the construction of housing units which fulfills all the objects and advantages sought therefor. The invention is not limited to the precise configuration described above. While the invention has been described as having a preferred design, it is understood that many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art without materially departing from the novel teaching and advantages of this invention after considering this specification together with the accompanying drawings. For example, the particular shapes and proportions of the elements of the block may be varied as desired. Accordingly, all such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by this invention as defined in the following claims.

[0063] All of the patents recited herein, and in the Declaration attached hereto, if any, are hereby incorporated by reference as if set forth in their entirety herein. The details in such patents may be considered to be incorporable at applicant's option, into the claims during prosecution as further limitations in the claims to patentably distinguish any amended claims from any applied prior art. 

What is claimed is:
 1. A concrete block for the construction of housing units, comprising: a top part, a bottom part, an opposite pair of sides, and an opposite pair of ends said opposite pair of ends having geometric shapes forming cavities of variable depth that allow housing the reinforcing steel and concrete necessary to guarantee the structural rigidity of an edification; a length of at least 80 centimeters along each of the opposite pair of sides; a plurality of interior holes of uniform geometric shape cut along the length of the block;
 2. The concrete block of claim 1, wherein said cavities of variable depth may be of any geometric form that allows the convenient location of the corresponding reinforcing steel and concrete.
 3. The concrete block of claim 1, wherein said cavities of variable depth are formed according to the use preferences or the requirements of the legal codes of the places of application.
 4. The concrete block of claim 1, wherein said interior holes are designed so as to allow the block to be cut in shorter dimensions without losing its application characteristics.
 5. The concrete block of claim 1, wherein the maximum length of the block depends on the capacity of the equipment used to produce the block and the operational maneuverability of the block.
 6. The concrete block of claim 5, wherein the width of the block varies according to the use preferences or the requirements of the legal codes of the places of application.
 7. The concrete block of claim 6, wherein the height of the block varies according to the use preferences or the requirements of the legal codes of the places of application. 8 The concrete block of claim 7, wherein the rest of the dimensions and interior geometry of the concrete block respond to the structural design technical criteria, industrial production process, transportation, management, and placement of the blocks.
 9. A concrete block for the construction of housing units, comprising: a top part, a bottom part, an opposite pair of sides, and an opposite pair of ends; special geometry cavities, wherein said special geometry cavities form cavities of variable depth and allow housing the reinforcing steel and the concrete necessary to guarantee the structural rigidity of an edification; and internal holes of modular geometry.
 10. The concrete block of claim 9, wherein said special geometry cavities may be of any geometric form that allows the convenient location of the corresponding reinforcing steel and concrete.
 11. The concrete block of claim 9, wherein said block's length is at least 80 centimeters.
 12. The concrete block of claim 10, wherein the modular geometry of the internal holes allows cutting the block in shorter dimensions without losing the application characteristics to satisfy the different dimensions in the housing units.
 13. The concrete block of claim 9, wherein said block's width is at least 10 centimeters.
 14. The concrete block of claim 9, wherein said block's height is at least 15 centimeters.
 15. The concrete block of claim 10, further comprising interior modular cells wherein said interior modular cells repeat the geometry of the ends when cutting said block transversally thereby adjusting the block to the dimensions required by a wall to be constructed and in dimensions of at least 5 centimeters.
 16. The concrete block of claim 15, further characterized by the convenient reduction of the transversal walls to a height with dimensions of at least 7 centimeters.
 17. The concrete block of claim 9, further characterized by the cutting or elimination of one of the various faces of the ends thereby creating joinders amongst the blocks;
 18. the concrete block of claim 17, wherein said joinder is a collinear joinder;
 19. The concrete block of claim 18, wherein said collinear joinder is an L shaped type joinder;
 20. The concrete block of claim 18, wherein said collinear joinder is a T shaped type joinder; 